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Hyundai HIMSEN H21/32, Instruction Book

The Hyundai HIMSEN H21/32 Instruction Book is a comprehensive manual that provides detailed information on how to effectively operate and maintain the product. You can easily download the manual for free from our website to ensure you get the most out of your Hyundai HIMSEN H21/32 experience.

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H21/32 

Page 

3/3

 

Fuel Injection Pump Assembly 

Maintenance Procedure 

연료

 

분사

 

펌프

 

어셈블리

 

정비점검

 

절차

 

Section No. 

 

M51000 

Rev. 

 

1A 

 

 

                                                  HYUNDAI HEAVY INDUSTRIES CO., LTD

.

         

Engine & Machinery Division                          05.04/KJC

 

 

3. 

연료

 

분사

 

펌프를

 

엔진

 

블록의

 

설치구로

 

운반하여

 

천천히

 

아래로

 

내린다

. 

인접해  있는  부품과  접촉하여  손상되지  않

도록  주의하십시오.

 

4. 

연료

 

캠과

 

크랭크

 

샤프트의

 

위치를

 

확인한다

. 

크랭

크

 

샤프트를

 

회전시켜

 

연료

 

분사

 

펌프의

 

롤러를

 

최저점에

 

위치시킨다

. 

이것은  연료  분사  펌프의  스프링력을  낮

추어서  펌프의  설치를  보다  쉽게  하기  위한  것입니다. 

5. 

연료

 

분사

 

펌프용

 

너트를

 

하나씩

 

대각방향으로

 

단

계별로

 

체결력을

 

증가시켜

 

체결한다

. 

 

체결  토크  : 170 Nm (molycote  도포)

 

6. 

고압

 

블록용

 

두개의

 

너트

                             

와

 

두개

의

 

볼트

                             

를

 

단계별로

 

체결력을

 

증

가시키면서

 

번갈아

 

체결한다

. 

체결  토크  : 3단계에  걸쳐  10 -> 30 -> 60 Nm   

(molycote  도포) 

체결  순서  : 

 

고압  블록을  설치할  때에는  연료가  누유

되지  않도록  주의하여  볼트를  체결해야  합니다. 

7. 

연료

 

공급

 

파이프용

 

블록

                             

을

  3

개의

 

볼트

                               

로

 

체결하여

 

고정시킨다

. 

체결  토크  : 40 Nm

 

8. 

소구경

 

파이프를

 

연결하고

, 

연료

 

랙과

 

연료

 

조정

 

레버를

 

연결한다

. 

랙의

 

움직임을

 

점검한다

. 

9. 

모든

 

커버를

 

닫는다

. 

 

 

 

 

 

 

 

 

 

 

3.  Move  and  Lower  the  fuel  injection  pump  slowly 

down through the bore of the engine block. 

Be  careful  not  to  be  damaged  by 

touching adjacent parts. 

4.  Check  the  position  of  fuel  cam  and  crankshaft. 

Turn the crankshaft until the roller of fuel injection 

pump is in lowest position of fuel cam. 

This is necessary to reduce the spring 

force of fuel injection pump for easier mounting. 

5.  Tighten  the  nuts  for  fuel  injection  pump  with 

increasing  torque  step  by  step  and  one  by  one 

diagonally. 

Tightening torque : 170 Nm (with molycote)

 

6.  Tighten two nuts                              and two bolts 

for  high  pressure  block  with 

increasing torque step by step alternatively. 

Tightening torque :10 -> 30 -> 60 Nm by three steps   

(with molycote) 

Tightening orders :   

When  mounting  high  pressure  block, 

tighten the bolts carefully not to leak fuel oil.

 

 

7.  Fix  the  block                            for  fuel  feed  pipes  by 

screwing three bolts 

Tightening torque : 40 Nm

 

8.  Connect small pipes and fuel rack and fuel control 

lever. Check movement of rack. 

9.  Close all covers. 

 

 

A52300 

 

A52300 

 

A52300 

 

A52300 

 

A52300 

 

A53000 

A52300 

 

A53000 

 

M53000 

 

M53000 

Summary of Contents for HIMSEN H21/32

Page 1: ...Division 1 Cheonha Dong Dong Gu Ulsan Korea http www hhi co kr http as hyundai engine com Engine After sales Service Dept Warranty Service TEL 82 52 202 7412 20 FAX 82 52 202 7581 82 52 250 9841 E ma...

Page 2: ...ormal Operating Data Normal Operation O02100 General Precaution and Warning O02200 Commissioning O02300 Preparations for Engine Starting O02400 Engine Starting O02500 Engine Load Up O02600 Engine Norm...

Page 3: ...nance G09400 Screw Tightening and Torques G09500 Hydraulic Screw Tightenings G09510 List of Hydraulic Jack Sets G09600 List of Standard Maintenance Tools G09610 List of Hydraulic Jack Spare Parts Comm...

Page 4: ...eat Ring Assembly M21120 Maintenance Procedure Valve Spindle Guide M21130 Maintenance Procedure Fuel Valve Bush M21140 Maintenance Procedure Intake Exhaust Valve Assembly Rocker Arm Assembly A21200 As...

Page 5: ...Instruction A33000 Assembly Drawing Part List A33100 Assembly Drawing Part List M33100 Maintenance Procedure Counter Weights M33200 Maintenance Procedure Flywheel Assembly A33300 Assembly Drawing Part...

Page 6: ...meters A45101 Assembly Drawing Part List Pressure Sensors Temperature Sensors Level Switches Speed Pick up Sensor A45200 Assembly Drawing Part List Engine Analog Sensor M45200 Maintenance Procedure Fu...

Page 7: ...sembly A62000 Assembly Drawing Part List M62000 Maintenance Procedure Lubricating Oil Filter Assembly A63000 Assembly Drawing Part List M63000 Maintenance Procedure L O Thermostatic Valve Assembly L O...

Page 8: ...ist Cooling Water Connection A77000 Assembly Drawing Part List A78000 Assembly Drawing Part List Supercharging System G80000 General Instruction M80000 Maintenance Procedure Intake Air System Assembly...

Page 9: ...Each sheet of this manual has its own Sheet No for identification which consists of Section No Page No and Revision Number It is recommended to use this Sheet No whenever communicating with engine mak...

Page 10: ...the safe operation or maintenance works Also should notify all safety guidance to other workers Additionally it must be followed general law for safety or precaution of the accident Symbol for Referen...

Page 11: ...onsignee 6 Item number 3 Engine type 7 Name of spare parts 4 Engine number 8 Quantity required The correct data inscriptions are essential for the quicker supply of spare parts properly When ordering...

Page 12: ...ormation Engine Nomenclature Section No G00400 Rev 1A HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 05 04 KJC Cylinder and Main Bearing Numbering Cylinder and Camshaft Bearing Numbering 1...

Page 13: ...e Clockwise viewed from Driving End Counterclockwise viewed from Free End Counter Clockwise Engine Counterclockwise viewed from Driving End Clockwise viewed from Free End Generator Side Driving End Fr...

Page 14: ...Cylinder kW kW 160 160 200 200 Cylinder Bore mm mm 210 Piston Stroke mm mm 320 Swept Volume per Cylinder dm 3 11 1 Mean Piston Speed m s 7 7 8 0 9 6 10 7 Mean Effective Pressure bar 24 1 23 1 24 1 21...

Page 15: ...ngine Cross Section Section No G01210 Rev 1A HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 05 04 KJC M 50 M 20 M 40 M 30 M 80 M 10 Engine Structure Air Gas System Combustion System Fuel In...

Page 16: ...ection Section No G01220 Rev 1A HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 05 04 KJC M 50 M 20 M 40 M 30 M 80 M 60 L O System Air Gas System Combustion System Fuel Injection System Eng...

Page 17: ...ets can be referred to the engine maker s shop test report or the like Performance Parameters and Evaluation As the engine produces power by burning fuel with continuous breathing air and exhaust gas...

Page 18: ...nt of air flow Increased pressure drop means reduction of charge air pressure which results lower cylinder pressure and more fuel consumption consequently Reduced amount of air flow results higher tem...

Page 19: ...ng of turbocharger is important for engine performance See manual for T C Back pressure after turbocharger is apt to be increased due to fouling of total exhaust system of the plant which also cause t...

Page 20: ...value changed considerably Otherwise engine may be operated in overloaded condition or lack of power Fuel quality and worn fuel system affects the maximum firing pressure which is one of the critical...

Page 21: ...tion the SFOC at MCR can be estimated according to the below mentioned formula SFOCamb SFOCISO dSFOC dSFOC 100 Tamb 25 0 05 Pamb 1000 0 007 TCW 25 0 07 LCV 42700 427 100 SFOCamb Specific fuel oil cons...

Page 22: ...an ISO 3046 1 standard condition the exhaust gas temperature after turbine could be estimated according to the below mentioned formula Taturbexh TaturbISO dTaturb dTaturb Tamb 25 1 5 TCW 25 0 7 Taturb...

Page 23: ...t engine after filter 4 0 5 0 bar 3 5 bar 3 0 bar Lub oil temperature inlet engine 60 70 80 Lub oil pressure inlet TC 2 0 4 0 bar 1 5 bar Oil mist detector option High level High level Lub oil level i...

Page 24: ...rovided to the right persons in order to be familiar with this engine before entering into operation and maintenance works Engine maker will provide training course for users if requested Unauthorized...

Page 25: ...sive gases or inflammable fluid especially during engine running or any repair works which cause spark such as welding work or similar Hot Opening of covers or loosening of some screws is not allowed...

Page 26: ...from not using genuine parts No Use of Other Usage All parts and articles of consumption should be only used in designated purpose Otherwise the engine maker will be free from any responsibility for...

Page 27: ...n Note on Commissioning 1 Installation of an engine should be carried out in the presence of representative s from engine maker and processed properly according to the engine maker s recommendations A...

Page 28: ...or maintenance Check the date when the last tightening of major fasteners Check if there is any loosened part and correct them if any Check all covers are closed Do not open the covers of the engine...

Page 29: ...g as below Starting on HFO over 60 Starting on MDO over 40 4 Preparation of Fuel System Drain fuel tanks for water and check filters Check fuel tank level and fill if needed Check cooling system for d...

Page 30: ...aul Check oil sump tank level and fill if needed Check valves and set them to operating position 6 Pre lubrication of the Engine Check lubricating oil temperature which should be heated up to 40 by he...

Page 31: ...d i e water or lubricating oil or fuel oil If there is any sign of escaping fluid through indicator cock wrap the indicator cock with cleaning rags to avoid the fluid scattering over And turn the cran...

Page 32: ...sition Check flexibility of each rack of fuel injection pump Rack of fuel injection pump should be returned to original position when pushing or pulling it manually Check mechanical fuel limiter for o...

Page 33: ...tion No O02300 Rev 1A HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 05 04 KJC Start Close indicator cock Press Start button again and check air running condition Air running is recommended...

Page 34: ...stop the engine immediately if needed during checking the condition of engine running Be sure to check the surroundings of the engine in case of Remote Start 2 Checking immediately after Starting Lis...

Page 35: ...engine Stop the engine after idle running for about 5 minutes Open the covers on engine block to inspect the internal sliding parts for abnormal overheating due to friction Inspect bearings for main...

Page 36: ...ater temperature over 60 can be loaded up from starting to 100 load immediately without any restriction However the sudden load up will take time to achieve stable frequency 3 Quick Load Up The quicke...

Page 37: ...Machinery Division 05 04 KJC Check the exhaust gas temperatures after cylinders and turbocharger inlet and outlet Check maximum firing pressure of each cylinder Operating data for each load step shou...

Page 38: ...port or the like Any unusually high or low tempera ture or pressure should be investigated Check operating condition of fuel supply system Check fuel oil temperature of engine inlet In case the engine...

Page 39: ...source from normal condensation or leakage of cooling water Check drain hole of cylinder head for the detection of cooling water or combustion gas between cylinder head and liner Check drain pipe for...

Page 40: ...l next start Otherwise the fuel should be changed over to marine diesel oil to avoid clogging of the fuel system due to cooled down of heavy fuel oil Load down to idle gradually by releasing generator...

Page 41: ...op solenoid valve In this case the engine will be stopped suddenly with loaded condition Therefore it is recommended to stop the engine manually instead of by Emergency Stop button 3 Manual Stop The e...

Page 42: ...other engine or cooling water heating system Otherwise warming up of the engine should be required before entering into normal service 2 Engine under Maintenance Wait until the engine cooled down befo...

Page 43: ...elow Run the pre lubricating pump for about 30 minutes at least once a week If humidity is high around the engine daily pre lubrication is recommended Turn crankshaft by more than 2 revolutions during...

Page 44: ...l starting Speed up to rated speed gradually by manual See Instruction Manual for Governor If not sufficiently warmed up run the engine until temperatures and pressures to be in normal operating condi...

Page 45: ...unning in is to fit the sliding surfaces for various load cases therefore do not run the engine with continuous load in initial stage In case of piston overhaul running in is also necessary to refit n...

Page 46: ...es Therefore long term low load operation should be avoided as possible However if it is inevitable to operate the engine at lower than 20 load for a long time continuously following measures should b...

Page 47: ...110 load on condition that a duration for maximum one hour per 12 hours However even in this intermittent overload running case following restrictions should be noted Do not adjust mechanical load lim...

Page 48: ...arting air supply line opened Check function of solenoid valves on air motor See Manual for Air Motor Starting air motor does not rotate Check function of solenoid valves on air motor See Manual for A...

Page 49: ...miter and start again manually Check movement of fuel rack control shaft and governor lever Press Reset button if fuel rack blocked by stop signal Lubricate linkages if stiff Adjust the levers if dist...

Page 50: ...05 04 KJC 1 2 3 Engine does not stop 1 Normal stop by control system failed Check function of control system and governor 2 Emergency stop failed Check if control air pressure is too low Check functio...

Page 51: ...Manual for Governor Auto stop due to the signal of turning gear engaged Check the limit switch and wiring for turning gear Auto stop due to low lubricating oil pressure Check lubricating oil system Au...

Page 52: ...lves stuck 2 Insufficient power of all cylinders Mechanical fuel limiter is in limiting position Check starting fuel limiter active Check fuel quality and fuel rack index Check fuel filters and clean...

Page 53: ...oler Clean if dirty Check the oil pump driving gears and thermostatic valves of the engine Repair or replace if needed Check oil filters and pressure drop Replace filters if needed Do not reuse Check...

Page 54: ...heated Adjust or repair if needed 5 Lubricating oil consumption is too low or oil level is increasing Lubricating oil contains fuel oil Check oil seal of fuel boost pump Replace if defective Check fue...

Page 55: ...ting line if air infiltrated Open valves for venting line if closed Repair supply system if air suctioned Check exhaust gas temperature and engine loading condition Release the load if overloaded Chec...

Page 56: ...temperatures of exhaust gas cylinder outlet Check fuel pump rack index Adjust for even distribution Check maximum firing pressure Adjust injection timing Check fuel valve by injection tester Clean or...

Page 57: ...some cylinders Check max firing pressure if too low Check piston rings if broken or damaged Black or Brown smoke Check fuel quality Check exhaust gas temperature Check fuel valves by injection tester...

Page 58: ...l injection pump and roller tappet hitching Check if fuel leaks excessively 2 Continuous unusual running noise Check if engine overloaded Check engine driven pumps and gears Check engine moving parts...

Page 59: ...CIMAC DC grade a centrifugal treatment system should be prepared The fuel should be cleaned and preheated before entering the engine as follows 2 Fuel Treatment 1 Purification Heavy fuel oil should be...

Page 60: ...g on the properties and the temperature of the fuel oil Maximum preheating temperature of HFO is limited up to 155 to avoid vapouring in fuel system Therefore the fuel should be heated according to th...

Page 61: ...re correct injection viscosity of 12 18 cSt the heater are to be controlled by an automatic viscosity controller before the fuel enters into the engine fuel system Higher or lower viscosity may cause...

Page 62: ...manufacturer which are not included in the CIMAC fuel quality CIMAC Recommendation No 21 2003 HFO MGO CIMAC H700 CIMAC DA CIMAC DB CIMAC DC 700 at 50 1 5 6 0 at 40 2 5 11 0 at 40 4 0 14 0 at 40 12 0 1...

Page 63: ...contaminants which are not removed by a centrifuging The special centrifuging sys tem should be installed to use the fuel oil with the maximum density 1010 kg m3 at 15 3 Sulfur It is important to keep...

Page 64: ...dium become corrosive ash after combustion these should be removed as possible Sodium compounds contributes to lower the melting point of vanadium ash which is very corrosive and harmful to exhaust va...

Page 65: ...water causes corrosion and cavitations of the fuel injection pump and fouling of the exhaust system and turbochargers The water content should be reduced to maximum 0 2 by centrifuging 9 Abrasive Par...

Page 66: ...x developed by Shell can be used to get the ignition quality of the heavy fuel oil If the value of CCAI is increased the ignition quality has decreased value The CCAI guidelines are as follows z The f...

Page 67: ...he HFO level with 50 90 and HFO temperature with 60 90 in HFO service tank Maintain the engine load with 30 70 Open the steam tracing and auto filter steam inlet valve in F O system Open the steam in...

Page 68: ...F O heater until 25 cSt viscosity in viscosity controller to protect the F O injection equipment against rapid temperature changes Close the steam tracing and auto filter steam inlet valve in F O syst...

Page 69: ...epending on the fuel used and the operating condition The recommendable brand names of the lubricants are listed separately and the basic requirements of new oil are as follows BN Base Number Alkalini...

Page 70: ...r penetrated or condensed water and salt wear particles and oxidation of oil itself etc Therefore regular checking of lubricating oil condition by supplier or specialist at least every three months in...

Page 71: ...h contribute to reliable engine operation 3 Condition of Lubricating Oil The condition of lubricating oil inside the engine is recommended to be within the following range The condition of the lubrica...

Page 72: ...lash point is below 150 there may be a risk of crank case explosion 4 Purifying of Lubricating Oil In addition to engine filter it is recommended to install a purifying device for the lubricating oil...

Page 73: ...there is no suction and discharging from one engine to another It is recommended to split up the time so that there is separation on all engines which are operating in turns NOTICE In any case cleanin...

Page 74: ...SUPERMAR 13TP 40 13 A B SUPERMAR 24TP 40 24 C SUPERMAR 30TP 40 30 C D SUPERMAR 40TP 40 40 D E Oil volume UG 8D 1 9 Liter UG 15D 2 3 Liter UG 25 2 1 Liter This list is given as guidance only Fuel grade...

Page 75: ...air and then becomes corrosive Chloride and Sulphate are corrosive even in the presence of an inhibitor Sea water or fresh water contaminated by sea water even in small amount is not allowed to be us...

Page 76: ...cooling efficiency which are not recommended for cooling water Only nitrite borate based inhibitors are recommended Do not mix the inhibitors of different types or properties Some inhibitors may be to...

Page 77: ...sample water by specialist is also recommended regularly at least every three month All checking results should be recorded and kept for trend evaluation which contribute to reliable engine operation...

Page 78: ...ning of the cooling system includes degreasing and descaling procedures which need special chemicals As the chemicals may be hazardous the cleaning of the cooling water system is recommended to be car...

Page 79: ...e normal level of the expansion tank Run the engine for settlement according to the inhibitor maker s recommendation or at least for 24 hours and then check the quality of the water for confirmation I...

Page 80: ...e is 45 maximum water content of charge air is 0 016 kg water kg charge air Using these values draw the line from point of the water content in the air to point of the water content in the charge air...

Page 81: ...for Base Frame and Resilient Mount Nut for Resilient Mount and Foundation Cylinder Unit and Con Rod Inspection M21200 Intake Exhaust Valve Seats and Guide Overhaul and Regrinding of Valve and Seat Ch...

Page 82: ...nspect Deflector Replace if needed Max life time 4 000 hours Check Plunger Assembly M52000 Fuel Injection Valve Check and Adjust the Opening Pressure Replace if necessary Maximum overhaul interval 2 0...

Page 83: ...1100 Piston ring scraper ring 1 x Z 1 x Z 1 x Z 1 x Z 2 x Z A15000 Flame ring 1 x Z 1 x Z 1 x Z 1 x Z 2 x Z A15000 Gasket between head and liner 1 1 1xZ 1 1xZ 1 1xZ 2 1xZ 2 2xZ 2 A15000 O rings for cy...

Page 84: ...T and LT pump 2 2 2 2 4 A71000 Mechanical seal for HT and LT pump 2 2 2 2 4 A71000 O rings for HT and LT pump set 2 2 2 2 4 A71000 O ring for pump connection piece 4 4 4 4 8 A74000 O ring for C W ther...

Page 85: ...Cooling water shut off and drain Fuel oil shut off and drain Lubricating oil circulation stopped and drain Pressure F O L O H T L T Air released Data for Maintenance Planning Some components can be d...

Page 86: ...0x1 5 91 400 Hydraulic jack M39x2 91 490 Support M39x2 91 210 Turing bracket for connecting rod Cylinder Unit M15000 91 230 Support device for connecting rod piston 2 4 0 91 400 Hydraulic jack M39x2 2...

Page 87: ...r M15100 91 260 Cylinder bore gauge 1 1 0 Water Jacket Cylinder Liner M15100 1 1 0 Fuel Injection Valve 91 130 Removal device for fuel injection valve 91 340 Nozzle tester 91 370 Cleaning tool for fue...

Page 88: ...t A 13 B 69 1 st ring a 0 13 0 175 0 5 1 st groove 6 35 2 nd ring b 0 1 0 145 0 5 2 nd groove 5 35 Oil scraper ring c 0 05 0 085 0 3 M31100 Piston ring and groove 3 rd groove 6 20 Piston pin and boss...

Page 89: ...2 0 7 a 0 2 0 7 M21210 Tappet and tappet guide B 50 b 0 025 0 08 0 2 M23000 Valve operating mechanism and tappet Tappet roller shaft and bearing C 30 D 45 E 26 F 10 c 0 020 0 066 d 0 050 0 091 e 0 15...

Page 90: ...hematic drawing Nominal Size Clearance Wear and Repair Limit Idle gear shaft and bushing A 100 B 117 a 0 156 0 262 b 0 150 0 350 0 4 0 5 Timing gear Backlash c 0 15 0 4 0 5 M35000 Other gear Backlash...

Page 91: ...Maintenance Section No G09300 Rev 2B HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 07 07 CJC 328 561 56 1 Cylinder unit Approx 404kg Cylinder liner Approx 70kg Cylinder head and rocker arm...

Page 92: ...9300 Rev 2B HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 07 07 CJC 570 770 Turbocharger type B H L Weight kg TPS48 448 511 926 129 TPS52 518 589 1074 187 TPS57 631 720 1311 300 Piston App...

Page 93: ...eel ass y M16x2 0 14 170 Nm A35000 115 Molycote Bolt for crankshaft gear wheel M20x2 5 30 340 Nm A35000 191 Molycote Bolt for idle gear wheel M16x2 0 14 170 Nm A35000 291 Molycote Nut M12x1 25 19 110...

Page 94: ...x2 5 27 280 Nm 240 Nm M20x2 5 30 400 Nm 340 Nm General bolts and nuts Strength grade 8 8 M22x2 5 32 550 Nm 450 Nm M6x1 0 10 14 Nm 10 Nm M8x1 25 13 35 Nm 25 Nm M10x1 5 17 70 Nm 50 Nm M12x1 75 19 120 Nm...

Page 95: ...a set of stud and nut which are designed properly for a hydraulic tool set The nut has pin holes for turning through the hole of support for jack as shown in fig 1 The engine also has some important s...

Page 96: ...Each screw needs own set of hydraulic jack and support for the corresponding screw size Depending on the working condition extension screw should be added for the jack as shown in fig 4 Fig 2 Hydraul...

Page 97: ...should be kept absolutely The screws and data for hydraulic tightening are listed in Put on protecting glasses against injuries due to failure of highly pressurized hoses and jack Before pressurizing...

Page 98: ...om the pump to the jacks via the distributing piece 7 Close the release valve of the hydraulic pump 8 Open air venting plug of the jack and check air venting by pumping 9 Close the venting plug and pr...

Page 99: ...is is important to provide space for loosening the nut 6 Close the release valve of the hydraulic pump 7 Open air venting plug of the jack and check air venting by pumping 8 Close the venting plug and...

Page 100: ...Hydraulic Untightening for Nut bar Stud length after Tightening H mm Stud for main bearing cap 91 400 91 460 M39 2 0 50 loctite 243 1200 1200 20 bar max 5 114 3 2 M13250 Side bolt for main bearing ca...

Page 101: ...70 M30 2 0 50 Molycote 950 950 20 bar max 5 80 2 1 M33200 Stud for counter weight 91 410 91 520 91 480 M30 2 0 50 Molycote 850 850 20 bar max 5 80 2 1 Stud for flywheel 91 410 91 520 91 480 M30 2 0 50...

Page 102: ...1 160 8 Lifting Jig for Piston M31000 1 0 7 91 170 9 Holding Piece for Crank Pin Bearing M32120 1 0 2 91 180 10 Suspension Device for Connecting Rod M32120 1 2 6 91 190 11 Guide Support for Connecting...

Page 103: ...0 1 7 8 91 390 Hydraulic Jack M39x2 for Cylinder Head M15000 31 Main Bearing Cap M13250 4 3 9 91 400 Hydraulic Jack M30x2 for Side Stud M13250 Connecting Rod Big End M31000 Counter Weight M33200 32 Fl...

Page 104: ...ept M15000 1 0 7 91 541 47 Distributing Piece 4 port M15000 1 1 91 542 48 High Pressure Hose L 550 All Cases 4 1 7 91 551 49 High Pressure Hose L 3000 All Cases 1 1 7 91 552 50 Removal Device for Exha...

Page 105: ...o G09600 Rev 1C HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 09 02 KGM Weight No Description Related Section Q ty kg Tool No Remarks 63 Removal Tool Locking Ring 1 91 940 64 Cleaning Hose...

Page 106: ...e for Valve Spindle complete M21120 1 91 740 10 Testing Mandrel for Piston Ring Grooves 5 35 M31100 1 91 750 11 Testing Mandrel for Scraper Ring Grooves 6 20 M31100 1 91 760 12 Testing Mandrel for Scr...

Page 107: ...k up Ring 1 91 405 O ring 1 91 406 Back up Ring 1 91 407 Quick Coupling 1 M30x2 Hydraulic Jack M30x2 Tool No 91 410 Part No Description Q ty 91 413 O ring 1 91 414 Back up Ring 1 91 415 O ring 1 91 41...

Page 108: ...k Spare Part Section No G09610 Rev 1B HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 08 06 KGM Size Item Part Angle Piece for Hyd jack M20x1 5 Angle piece for Hydraulic Jack M20x1 5 Tool No...

Page 109: ...ev 1B HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 05 04 KJH Part List Q ty Eng Item No Description 5 cyl 6 cyl 7 cyl 8 cyl 9 cyl Weight kg Remarks See Note 001 Common base frame 1 1 1 1...

Page 110: ...Assembly Drawing Part List Section No A11100 Rev 1A HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 05 04 KJH Part List Item no Description Q ty Mount Weight kg Remarks See Note 001 Bolt 4 0...

Page 111: ...tem the generating set is mounted foundation by resilient mounting coupled on a bracket of a common base frame shaped conical For all equipments or a generating set are not influenced external system...

Page 112: ...nting The dimension of steel shim should be exactly measured and extended at least 25mm 2 Insert two steel shims between the foundation and bottom of conical mounting The above steel shim should be lo...

Page 113: ...e below No 2 Otherwise perform below after clinging the resilient mounting to the base frame 1 Fix the top casting to the bracket of the base frame by using 4 bolts 2 Remove Protection cap and loosen...

Page 114: ...nting is fully deflected Fig 2 Fig 2 6 The variation in laden height should not be exceed 2mm and should ideally be less to ensure that individual mountings are not overloaded Also the difference betw...

Page 115: ...mble the resilient mounting and the steel shim by getting down the generating set 10 Bring the internal buffer into contact with the steel shim completely by rotating it clockwise direction 11 Make th...

Page 116: ...s normal perform from the below No 2 Otherwise perform below after clinging the resilient mounting to the base frame The height of supporting steel shim used for replacement of resilient mounting shou...

Page 117: ...rned freely after getting down the engine NOTE If the internal buffer is not turned freely make it release by turning it clock wise direction after remove the partial load of those resilient mounting...

Page 118: ...ng bolts then install the steel shim And then bring the generating set completely contact with the foundation by getting down the generating set 10 Be contacted the internal buffer with the steel shim...

Page 119: ...e frame Fig 1 3 Lift the generating sets for remove a steel shim At this time secure a sufficient place for replace a damaged resilient mounting 4 Replace a damaged resilient mounting NOTICE whenever...

Page 120: ...Loose mounting bolt 3 Damages on a rubber element Follow Up Measures Clearance Inspection Inspect a gap between a steel shim and a internal buffer should be 4mm by means of a feeler gauge Fig 1 Result...

Page 121: ...d top lock ring 4 Turn a buffer 2 to clockwise direction until it is contacted with a steel shim Turn a buffer full 4 turns to counter clockwise direction until it is contacted with a base casting Mak...

Page 122: ...Air channel of the engine block distributes the air to each cylinder Lubricating oil flows into casting oil channel of the engine block from the feed module and is distributed to every main bearing Th...

Page 123: ...H21 32 Page 1 2 Engine Block Assembly Drawing Part List Section No A13000 Rev 1A HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 05 04 PDS...

Page 124: ...2 14 16 18 20 22 241 Side bolt M30x2 14 16 18 20 22 242 Nut M30x2 14 16 18 20 22 249 O ring 14 16 18 20 22 291 Cylindrical pin 7 8 9 10 11 311 Cylinder head bolt M39x2 20 24 28 32 36 312 Nut M39x2 20...

Page 125: ...t Section No A13250 Rev 1A HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 05 04 PDS Part List Q ty Eng Item No Description 5 cyl 6 cyl 7 cyl 8 cyl 9 cyl Weight kg Remarks See Note 251 Main...

Page 126: ...hydraulically at the same time Loosening procedure Loosening pressure 870 bar max 893 bar Hydraulic tool 3 Dismount the hydraulic tools and take out the studs and nuts from the engine 4 Install lifti...

Page 127: ...he hydraulic tools 7 Lower the main bearing cap slowly by unscrewing the nuts 8 Take out lower bearing from the cap carefully 9 Turn the crankshaft and mount the fitting plug on the oil hole of the jo...

Page 128: ...eans of a ball anvil micrometer and check the wear limit 5 Keep the record of the measurements and inspection results If there is any sign of abnormality on the journal or bearings it should be invest...

Page 129: ...ling the fitting plug Do not mix the bearings with other counter part The bearings should be matched with correct pairs 8 Mount the main baring cap by lifting and screwing the nuts 9 Mount side studs...

Page 130: ...ul not to damage the thrust bearings when measuring by filler gauge Maintenance of the Thrust Bearings The clearance between thrust bearing and crankshaft should be within the tolerance Tolerance If t...

Page 131: ...and dismounting Depending on the situations one of the maintenance concepts can be selected for convenience For example when purpose of maintenance is clearly limited to a certain component of a cyli...

Page 132: ...z The cylinder unit comprises following components z Cylinder Head z Valve Rocker Arm z Cylinder Liner and Water jacket z Piston and Connecting Rod z Valve Train z Fuel Injection Equipments This sect...

Page 133: ...Unit from the Engine 1 Disconnect connection pipes by moving axially the direction of arrow as shown in fig 1 2 Dismount insulation and V clamp on exhaust duct of cylinder head 3 Disconnect small pip...

Page 134: ...for both sides of the cylinder to be dismantled 7 Loosen four nuts for connecting rod upper stud hydraulically and then dismount the nuts and studs Loosening procedure and Loosening pressure 1170 bar...

Page 135: ...ion pump and water jacket by them This is necessary to avoid fuel injection pump extruded upward by its spring after loosening the fixing nuts for the fuel injection pump So the high pressure pipe blo...

Page 136: ...nd ready for normal service Make sure that covering tapes or the like removed All O rings should be checked and replaced by new ones which also should be cleaned and greased before mounting the cylind...

Page 137: ...ater jacket to cylinder head If these bolts are not removed water jacket may be overstressed and damaged during engine operation 9 Screw the four nuts for fuel injection pump and four bolts for water...

Page 138: ...Tightening torque 170 Nm 17 Connect connection pipes by moving axially 18 Mount V clamp and insulation on exhaust duct of cylinder head 19 Fix the block for fuel feed pipes by screwing three bolts Tig...

Page 139: ...le cast iron and mounted on the engine block The water jacket provides not only cooling water flow channel between cylinders but also combustion air passage from engine block to cylinder head The wate...

Page 140: ...HEAVY INDUSTRIES CO LTD Engine Machinery Division 06 04 SWC Part List Item No Description Q ty Cyl Weight kg Remarks See Note 211 Cooling water jacket 1 62 0 901 O ring 1 902 O ring 1 906 Hex head bol...

Page 141: ...ivision 06 04 SWC Parts List Item No Description Q ty Cyl Weight kg Remarks See Note 111 Cylinder liner 1 70 1 122 Flame ring 1 191 Sealing ring 1 192 O ring 1 193 O ring 1 903 O ring 2 931 Connection...

Page 142: ...liner by water jacket the water jacket should be dismantled in advance See Dismounting of a cylinder unit from the engine in Mounting Cylinder Liner on Water Jacket Before mounting the cylinder liner...

Page 143: ...r liner bore at regular interval and keep the records Check the bore is within the wear limit The measurements for both diameters of trans verse and longitudinal direction should be taken at three poi...

Page 144: ...d and liner is dismantled check the sealing faces carefully and if necessary grinds the surfaces as shown in fig 4 Sealing faces for grinding 1 Cylinder liner a 2 Cylinder head b 3 Engine Block c Grin...

Page 145: ...novation is made in the workshop Prior to honing deposits of coke and possible wear edges at the top of the liner must be removed by scraping Honing tool A used flame ring must be used during the honi...

Page 146: ...TD Engine Machinery Division 07 03 CJY 6 6 40 60 In order to achieve a required angle between honing grooves see fig 6 the vertical speed of a flex honor is adjusted Refer to the below calculation for...

Page 147: ...Y The procedure must be continued until the cylinder wall is covered by honing grooves and the surface has a slightly matt appearance without any signs of glaze During the honing it is important to lu...

Page 148: ...ucture made of cast iron and installed at free end side of the engine The feed block provides cast in passages and spaces for mounting the equipments for each fluid system Hence the engine internal ci...

Page 149: ...USTRIES CO LTD Engine Machinery Division 05 04 KJC A62000 A84000 T C Manual A71000 A61000 A74000 A63000 A64000 A63000 Fig 2 Equipments for feed module Turbocharger Charger Air Cooler L O Cooler L O Pu...

Page 150: ...Division 05 04 PDS Part List Item No Description Q ty Eng Weight kg Remarks See Note 850 Cover 1 851 Cover 2 854 Cover 1 855 Packing 2 858 Packing 1 860 Cover 1 861 Packing 1 912 Bolt M12x30 24 913 S...

Page 151: ...n 05 04 PDS Parts List Item No Description Q ty Eng Weight kg Remarks See Note 852 Cover 1 853 Cover 1 856 Cover 1 857 Packing 1 870 Cover 1 871 Packing 1 891 Packing 1 892 Packing 1 912 Bolt M12x30 2...

Page 152: ...HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 05 04 PDS Part List Item No Description Q ty Eng Weight kg Remarks See Note 110 Sealing cover 1 230 123 Oil throw ring 1 124 O ring 2 62x422 1...

Page 153: ...D Engine Machinery Division 10 04 KHA Part List Item No Description Q ty Eng Weight kg Remarks See Note 5 cyl 6 cyl 7 cyl 8 cyl 9 cyl 320 Crankcase cover for relief v v 2 2 3 3 4 360 Safety valve 2 2...

Page 154: ...8 10 11 13 14 330 Gearcase cover down 2 2 2 1 1 4 56 340 Camshaft room cover 5 6 7 8 9 3 82 350 Gearcase cover up 1 1 1 1 1 3 8 370 Gearcase cover down 1 1 381 Stud M16x40 42 50 58 66 72 382 Nut M16 4...

Page 155: ...liner and fixed by four hydraulic studs on the engine block Cylinder head is made of ductile cast iron and has cast in passages for cooling water intake air and exhaust gas Cylinder head also has dril...

Page 156: ...ng water Cylinder head is a part of combustion chamber which should be overhauled and maintained at regular interval for reliable operation with high performance Cylinder head has a check hole against...

Page 157: ...Cylinder Head Assembly Assembly Drawing Part List Section No A21100 Rev 1B HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 06 05 CJC 119 111 131 116 100 134 903 133 114 117 132 904 115 113...

Page 158: ...g Remarks See Note 100 Cylinder head complete water tight Item no 111 904 111 Valve insert inlet 2 0 23 112 Valve insert exhaust 2 0 40 113 Valve guide 4 0 35 114 Bush for fuel valve 1 0 42 115 Closin...

Page 159: ...n No A21100 Rev 1B HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 06 05 CJC Part List Item No Description Q ty Cyl Weight kg Remarks See Note 800 Cylinder head cover complete 1 801 Cylinder...

Page 160: ...fuel injection pump Put on clean rag around fuel high pressure block and wrap the block against fuel oil dropping After dismounting fuel high pressure block put a covering tape on the outlet of fuel...

Page 161: ...up onto a crane as shown in fig 2 Lifting Tool After remounting a stud for top cover support and Install the lifting jig 3 Lift up the cylinder head and put it on a stable working stand Optional Moun...

Page 162: ...d before mounting O rings on the bottom of cylinder head O rings on the connection pieces of water jacket O ring on the cylinder liner 6 Clean the sealing ring on top of the cylinder liner and coat se...

Page 163: ...to be smaller for easier welding of the valve and the seat ring 2 Mount the scrapped valve spindle on the head 3 Weld the valve spindle to the seat ring diagonally by means of electric beam welding Pr...

Page 164: ...by cooling or by pressing as shown in fig 2 When cooling the seat ring to be 190 by means of liquid nitrogen When pressing use tool Optional 4 Grind the seat ring by valve grinding tool See Grinding o...

Page 165: ...0 6 Grind the seat ring by valve grinding tool See Grinding of the seating surface in M21200 M21200 7 Check water leakage around the new valve seat by hydraulic pressure test Test pressure 7 10 bar Re...

Page 166: ...ed by a new one When extracting and fit ting the valve guide same tool can be used as shown in fig 3 1 Mount the tool as shown in fig 3 Fit Removal device Optional 2 Press or knock the tool by means o...

Page 167: ...guide to 70 by liquid nitrogen 5 Fit valve guide by means of the tool with hammering softy on the tool as shown in fig 4 Be careful not to damage the valve guide during hammering 6 Insert a new O rin...

Page 168: ...ol as shown in fig 1 Removal device 2 Hook the edge of locking ring and extract the locking ring by tool as shown in fig 2 3 Mount the tool as shown in fig 3 Removal device 4 Press or knock the tool b...

Page 169: ...rt List Item No Description Q ty Cyl Weight kg Remarks See Note 201 Inlet valve spindle 2 0 93 202 Exhaust valve spindle 2 0 85 203 Valve spring 4 204 Roto cap 4 0 29 206 Conical clamping piece 4 0 02...

Page 170: ...Rocker Arm Assembly Assembly Drawing Part List Section No A21200 Rev 1B HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 06 04 CJC 313 315 312 314 316 330 419 415 416 310 320 901 902 317 907...

Page 171: ...arm body intake 1 2 38 312 Adjusting screw 2 0 12 313 Ball seat 2 0 09 314 Nut 2 315 Clip spring 2 316 Fine threaded plug 4 317 Bush for rocker arm 2 320 Rocker arm complete exhaust 1 2 63 321 Rocker...

Page 172: ...e cylinder head Whenever dismantling it is recommended to overhaul the four valves at the same time Hence the tool for dismantling valves is adequate for this purpose 1 Mount tool for dismantle as sho...

Page 173: ...valve guide The O rings should be replaced by new one at every overhaul of valve spindle If there is any blow by through the valve seats the O ring may be overheated and also should be replaced by a...

Page 174: ...g compound on both seating surfaces and rub the surfaces by rotating valve manually several times Then clean the surfaces and check the conditions Depending on the condition of the seating surface the...

Page 175: ...ater should be supplied on the grinding surface After grinding crack test on seating surface for example dye penetration test should be carried out The seating surface should be free from any crack Ch...

Page 176: ...ould be checked periodically as frequent as possible In addition be sure to carry out the adjustment whenever cylinder head remounted and check again after about 50 running hours firstly at least The...

Page 177: ...ock nuts 1 3 and adjusting screws 2 4 4 Press the non adjusting side of yoke in order to contact with top of valve stem A firmly as shown on fig 1 5 While contacting A by pressing rotate the adjusting...

Page 178: ...he both clearances again for confirmation Adjustment of Valve Clearance After adjustment of the yoke balancing continue to adjust valve clearance as follows 1 Check the wearing parts of rocker arm ass...

Page 179: ...oom Front 1 1 1 1 1 14 0 822 Cover for fuel pump room Middle 1 1 2 2 11 8 823 Cover for fuel pump room Middle 1 1 1 824 Cover for fuel pump room After 1 1 1 1 1 825 Grip 6 7 8 9 10 826 Bolt 6 7 8 9 10...

Page 180: ...st Section No A22000 Rev 1B HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 06 04 CJC Part List Item No Description Q ty Cyl Weight kg Remarks See Note 501 Indicator valve M20xP 2 1 503 Conn...

Page 181: ...o Description Q ty Cyl Weight kg Remarks See Note 100 Push rod assembly 2 1 45 101 Push rod 2 1 25 102 Ball seat push rod 4 0 10 200 Swing arm assembly 2 3 01 See page 2 2 205 Swing arm piece bolt 2 0...

Page 182: ...A23000 Rev 1A HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 05 04 CJC Part List Item No Description Q ty Cyl Weight kg Remarks See Note 201 Swing arm body 2 2 27 202 Roller 2 0 31 203 Rol...

Page 183: ...assembly has two rollers and bearings for intake and exhaust valves which should be overhauled periodically and replaced by new ones if damaged or worn See Wear limits of The swing arm is hung under...

Page 184: ...shows the lubricating oil flow in valve trains and cylinder head The lubricating oil supplied from oil channel of the engine block flows into fuel injection pump swing arm rollers and valve trains su...

Page 185: ...escription 5 cyl 6 cyl 7 cyl 8 cyl 9 cyl Weight kg Remarks See Note 115 Stud bolt 30 42 56 72 90 0 13 116 Nut 60 84 112 144 180 0 03 215 1 216 1 217 1 218 1 219 End cover for camshaft 1 3 05 315 1 316...

Page 186: ...a stud should be secured by loctite 243 before retightening them Tightening torque 270 Nm Torque spanner Interchangeable head Inspection of Cams and Bearings Running surfaces of cams and bearings of e...

Page 187: ...de door b as shown in fig 1 1 Loosen all rocker arms and then dismantle all push rods and swing arms 2 Dismantle timing gear of camshaft See This is necessary to move camshaft axially whether the cams...

Page 188: ...mshaft and mount corresponding cylinder Check positioning markings on the flanges of camshaft and accord the markings with mating camshafts And remount after according TDC markings on both camshafts a...

Page 189: ...Drawing Part List Section No A25300 Rev 1A HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 05 04 KJC Part List Q ty Eng Item No Description 5 cyl 6 cyl 7cyl 8cyl 9 cyl Weight kg Remarks See...

Page 190: ...ces Cool down the bearing shell to 90 lower than frame temperature by dry Ice or the likes Insert bearing shell and accord the oil hole of bearing shell and frame by means of a pin with diameter 9 5mm...

Page 191: ...ring grooves which need careful overhaul inspection The connecting rod is made of special die forged steel which is composed with a three piece marine head type All fasteners are tightened by hydrauli...

Page 192: ...of connecting rod should be dismantled in advance Dismantling of big end part of connecting rod is not necessary and not recommended only for dismantling piston The lubricating oil is supplied for co...

Page 193: ...oval device 3 Install lifting jig on the piston crown as shown in fig 1 Lifting jig 4 Turn the crankshaft to 25 approximately 5 Install clamping support on connecting rod shaft and big end part Clampi...

Page 194: ...ing support 10 Lift up the piston together with connecting rod shaft slowly and carefully 11 Move and place the piston together with connecting rod shaft at stable working stand Optional as shown in f...

Page 195: ...edure Make sure that covering tapes or the like removed 1 Before assembling install guiding jig on the cylinder liner for preventing piston rings from any damage as shown in fig 4 Guiding jig 2 Instal...

Page 196: ...g bracket 8 Turn the crankshaft to 25 approximately 9 Check pre tightening of four studs for connecting rod shaft and tighten them Pre tightening torque 50 Nm with molycote 10 Tighten two diagonal nut...

Page 197: ...0 bar max 998 bar Hydraulic tool 3 Install guide support on bottom of the engine as shown in fig 6 Guide support 4 Turn the crankshaft to 5 approximately 5 Dismount the turning bracket 6 Dismantle the...

Page 198: ...efore reassembling 3 Inspect any damages in the joint faces between the connecting rod shaft and big end upper part Take care to handle connecting rod shaft and big end parts 4 Inspect any damages in...

Page 199: ...d bearings should be cleaned and coated with clean lubricating oil before mounting 1 Mount upper and lower bearings on the their bearing housings 2 Assemble the big end upper and lower part 3 Install...

Page 200: ...em no 111 117 111 Piston crown 1 6 72 112 Piston skirt 1 17 07 113 Stud bolt 2 0 08 114 Nordlock washer 2 0 01 115 Hexagon nut 2 0 03 116 O ring 1 117 Spring pin 1 120 Piston pin complete 1 9 5 130 Re...

Page 201: ...of a piston and connecting rod in 2 Install I bolt on the piston crown and hook up onto a crane 3 Lift up the piston together with connecting rod shaft from working stand and slow down the joint faces...

Page 202: ...s carefully 8 Inspect the piston for any abnormal marks carefully 9 Inspect the piston pin and the small end bush See Small end bush overhaul in Inspection of Piston Bolt Tension 1 Loosen piston stud...

Page 203: ...tening direction If the nuts can turn any more replace by new ones stud nut Used nordlock washers to be scraped and new ones should be applied during re assemblies Assembling of Piston Pin and Piston...

Page 204: ...relation to each other 6 Inspect the piston rings for wear carefully as shown in fig 3 If piston rings exceed the wear limit and or if the piston has any abnormal mark then replace by new one 7 Mount...

Page 205: ...No Description Q ty Cyl Weight kg Remarks See Note 100 Connecting rod complete 1 54 3 Except item no 120 111 Connecting rod Shaft 1 22 3 112 Connecting rod Big end 1 26 7 120 Big end bearing 1 1 8 130...

Page 206: ...arts studs hydraulic ally and then dismount the nuts and studs Loosening procedure Loosening pressure 970 bar max 998 bar Hydraulic tool 4 Install handling pipes on supports and insert locating pins i...

Page 207: ...11 5 45 8 Mount bracket on engine block as shown in fig 4 Bracket 9 Turn the crankshaft slowly to cam side 5 approximately 10 Fix the big end upper part and the bracket with bolt 11 Turn the cranksha...

Page 208: ...ocedure The joint faces of big end parts and bearings should be cleaned and coated with clean lubricating oil before mounting 1 Mount the upper bearing to its housing 2 Loosen and take out the bolt fo...

Page 209: ...xceeded contact HHI s Diesel Engine A S for replacement In case of replacing the bush use the removal device as shown in fig 6 This tool optional can be ordered from engine maker During removing a bus...

Page 210: ...ankshaft main bearing crank pin big end bearing of connecting rod and piston At the free end of crankshaft there is a gear wheel for driving of pumps such as lubricating oil pump and cooling water pum...

Page 211: ...H21 32 Page 1 1 Crankshaft Assembly Assembly Drawing Part List Section No A33000 Rev 1A HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 05 05 HSY A33400 A33100 A35000 A33300 Generator...

Page 212: ...Crankshaft 5cyl 1 1001 116 Crankshaft 6cyl 1 1140 117 Crankshaft 7cyl 1 1278 118 Crankshaft 8cyl 1 1416 119 Crankshaft 9cyl 1 1554 190 Plug screw 5 6 7 9 9 191 Plug screw 1 1 2 2 1 210 9 12 14 16 18...

Page 213: ...tions which need to be as same as possible for more exact comparison The measuring should always be carried out at cold engine Before measuring the temperature of the dial gauge should be nearly the s...

Page 214: ...al and horizontal deflections are as follows z Vertical deflection dv T X Y 2 z Horizontal deflection dh P S If vertical and horizontal deflections exceed the permissible limits 0 1 0 22 mm realign th...

Page 215: ...1 100 mm THE PERMISSIBLE DEFLECTION OF CRANKSHAFT Unless otherwise stated the values refer to cold engine New or recently overhauled engine permissible 26 12 For the crank nearest the flywheel Cold C...

Page 216: ...ction 3 Loosen and dismount two nuts for counter weight studs hydraulically at the same time Loosening procedure Loosening pressure 870bar max 893 bar Hydraulic tool 4 Dismount the counter weights Cle...

Page 217: ...ure Counter weight should be cleaned and coated with clean lubricating oil before mounting 1 Prior to mount counter weights place locating pin into the crank web 2 Mount counter weight to the cranksha...

Page 218: ...4 HSY Part List Item No Description Q ty Cyl Weight kg Remarks See Note 320 Gear rim 1 52 0 331 Stud for flywheel 16 1 25 332 Nut 16 333 Cylindrical pin 1 334 O ring for side bolt 16 335 Hex socket he...

Page 219: ...chinery Division 09 02 PMU Part List Item No Description Q ty Eng Weight kg Remarks See Note 402 Hexagon bolt 18 0 40 407 26 8 For 720 750 rpm 409 Pump drive gear 1 22 6 For 900 1000 rpm 493 Nut 18 49...

Page 220: ...ar When the crankshaft rotates one time the camshaft rotates a half in the same direction through the idle gear The camshaft drive gear is fixed to the camshaft through disc The idling gear consists o...

Page 221: ...YUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 07 08 YJH Item No Description Q ty Eng Weight kg Remarks See Note 222 Orifice for idle gear lub nozzle CW 1 0 5 Engine rotation CW 232 Orifice...

Page 222: ...Y INDUSTRIES CO LTD Engine Machinery Division 07 08 YJH Part List Item No Description Q ty Eng Weight kg Remarks See Note 110 Crankshaft gear ass y 1 40 Incl item 111 115 116 111 Crankshaft gear 1 39...

Page 223: ...08 YJH Part List Item No Description Q ty Eng Weight kg Remarks See Note 210 Idle gear ass y 1 44 Incl item211 212 213 211 Idle gear big 1 24 212 Idle gear small 1 18 213 Bearing bush for idle gear 1...

Page 224: ...hinery Division 07 08 YJH Part List Item No Description Q ty Eng Weight kg Remarks See Note 311 Camshaft gear 1 31 331 Cam thrust bearing ass y 1 20 333 Thrust shaft for camshaft 1 10 393 Hex bolt 10...

Page 225: ...not adjustable and only needs correct alignment when remounting of the gears after maintenance Misalignment of even one tooth causes touching of piston and valves which results serious damage of the t...

Page 226: ...and oil spray nozzle as well as shown in fig 2 4 Lay the camshaft gear on the idle gear and roll down to the mounting position with the camshaft 5 Check TDC marking on the camshaft gear which should b...

Page 227: ...of camshaft gear and flywheel should be as shown in fig 3 TDC marking means TDC of No 1 cylinder 9 Assemble all sets of joint screws and tighten them one by one diagonally Coat Molykote on the thread...

Page 228: ...4 YJH 10 2 10 Turn the flywheel and check feeling of the rotation If any abnormal resistance is detected during turning stop the turning immediately and return to previous position Then recheck TDC ma...

Page 229: ...two deflectors from fuel injection pump in order to check its fuel ports then remove the rest fuel oil in pump using compressed air and open the window for flywheel scale See Fig 2 3 See inside a defl...

Page 230: ...ision 08 05 RSK 8 6 8 Normally their average value is considered as the representative fuel injection timing of the engine Fig 4 Read flywheel scale from TDC TDC Fig 2 Remove deflectors from FIP Fig 3...

Page 231: ...cover up item no A19300 350 and the window for flywheel scale 2 Turn crankshaft anticlockwise if it is required to advance fuel injection timing by means of a turning gear in order to see position ma...

Page 232: ...position mark is adjustable only in the range of index and index Crank angle 2 degree corresponds to cam angle 1 degree 8 Close the gear case cover up and the window for flywheel scale 9 If you turned...

Page 233: ...D Engine Machinery Division 08 05 RSK z M51101 z If adjusting fuel injection timing of some cylinders is needed see M51101 _ Gear side Disc side Disc for camshaft gear Camshaft Gear Camshaft A Fig 5 P...

Page 234: ...ation The compressed air supplied from the air reservoir is lowered to a proper pressure through reducing valve around staring air motor which is used for starting and stopping the engine See As the p...

Page 235: ...reaches predetermined speed fuel oil is injected into the combustion chamber for self rotating Then starting is completed and the pinion of the air starting motor is disengaged from the gear rim at p...

Page 236: ...e there are two ways of moving fuel racks to stop position Zero index as shown in fig 2 The one is by the mechanical stop which pull the racks to stop position by the governor or the manual control le...

Page 237: ...pplicable for the engine depending on the engine applications Therefore please refer to the separated manual for the specific governor system However there are three types of the governor basically as...

Page 238: ...inkages transfer the rotation of governor terminal shaft to move the fuel rack in order to control quantity of fuel injection by governor as shown in fig 3 Though the fuel control linkages were adjust...

Page 239: ...replacing the governor with new one the gain values of governor should be checked and adjusted to avoid hunting which should be carried out only by governor maker The arm length of terminal shaft also...

Page 240: ...l fuel limiter is installed on the engine to avoid ex cessive fuel injected into cylinders The fuel limiter is installed near the governor and limits rotation of the lever on fuel control shaft agains...

Page 241: ...en the lock nut Otherwise setting value of the limiter may be changed which may cause serious accidents 2 Starting fuel limiter During starting period the turbocharger is out of normal operation and t...

Page 242: ...olenoid valve to supply compressed air to push the fuel limiter piston as shown in fig 5 The limiting position can be adjusted by guide when loosening locking screw Be sure to lock the locking screw a...

Page 243: ...H21 32 Page 1 7 Fuel Control Linkage Assembly Drawing Part List Section No A41000 Rev 2C HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 08 06 KIK A41000 A41000 A41000 A51000...

Page 244: ...Q ty Eng Weight kg Remarks See Note 110 Governor complete 1 111 Governor terminal lever 1 112 Lever 1 113 Grip 1 155 Bolt 1 156 Bolt 1 157 Nut 2 158 Washer 2 159 Bolt 1 161 Bolt 1 162 Nut 1 163 Sprin...

Page 245: ...chinery Division 08 06 KIK Part List Item No Description Q ty Eng Weight kg Remarks See Note 114 Lever 1 150 Air cylinder 1 151 Safety cover 1 152 Socket head bolt 4 153 Nut 4 154 Cap nut 1 160 Bolt 1...

Page 246: ...4 7 Governor Driving Gears Assembly Drawing Part List Section No A41000 Rev 2C HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 08 06 KIK 209 208 201 203 226 228 227 210 222 202 225 220 221...

Page 247: ...Q ty Eng Weight kg Remarks See Note 200 Governor drive assembly 1 19 7 Item no 201 229 201 Housing 1 202 Gleason bevel gear 1 203 Bevel gear 1 204 O ring 1 205 Cover 1 208 Ball bearing 1 209 Retainin...

Page 248: ...aft L 2020 1 301 Shaft L 2350 1 301 Shaft L 2680 1 301 Shaft L 3010 1 301 Shaft L 3340 1 320 Shaft support with item no 322 6 7 8 9 10 322 Bush 6 7 8 9 10 323 Hex socket head bolt 12 14 16 18 20 341 L...

Page 249: ...ngine Machinery Division 08 06 KIK Part List Item No Description Q ty Eng Weight kg Remarks See Note 601 Ball joint 8 1 602 Ball joint 1 603 Nut 2 604 Pull rod 1 605 Guide ring 1 606 Set screw 1 607 C...

Page 250: ...H21 32 Page 1 3 Starting Air Reducing Valve Assembly Drawing Part List Section No A42000 Rev 1A HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 05 04 DYJ...

Page 251: ...plete 1 401 Locking nut 1 402 Spring washer 4 403 Manual handle 1 404 Locking nut 1 405 Adjust screw 1 406 Nut 6 407 Stud screw 6 408 Name plate 1 409 Spring case 1 410 T spring seat 1 411 Spring 1 41...

Page 252: ...A HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 05 04 DYJ Part List Item No Description Q ty Eng Weight kg Remarks See Note 201 Strainer complete 1 301 Body 1 302 Nut 4 303 Gasket 1 304 Sc...

Page 253: ...A HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 05 04 JSC Part List Item No Description Q ty Eng Weight kg Remarks See Note 101 Starting air motor 1 109 Hex head bolt 3 110 Washer 3 A42300...

Page 254: ...cription Q ty Eng Weight kg Remarks See Note 301 Body 1 303 Shaft 1 304 Locking device 1 305 Pinion 1 306 Bush 1 307 Bush for gear wheel 1 308 Guide pin 1 309 Spring 1 311 Hex socket head bolt 3 312 H...

Page 255: ...05 VAH Description The starting box is mounted on the engine s control side On front of the box there are the following indications pushbuttons Indication of engine and turbocharger RPM Pushbutton fo...

Page 256: ...ng the diesel engine Throughout the starting cycle the start button must be activated The air starter is automatically disengaged when the diesel engine exceeds 140RPM If the start butt on is disengag...

Page 257: ...ith Local Control Panel Section No G45000 Rev 2B HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 09 05 VAH Manual emergency Stop The Manual emergency stop button is connected to the emergenc...

Page 258: ...For measuring the engine s RPM a pick up sensor mounted on the engine is used giving a frequency depending on the RPM To be able to show the engine s RPM on a digital tachometer where the signal is tr...

Page 259: ...gh a relay One for synchronizing and one for start stop of pre lub Oil pump or alarm blocking at start stop Over speed When the engine speed reach the set point for electric overspend the converter gi...

Page 260: ...imit control When the engine speed reach 25RPM the converter gives a fuel limit control signal Turbocharger RPM signal For measuring the turbocharger RPM a pick up sensor mounted on the engine is used...

Page 261: ...ion 05 04 DYJ Part List Item No Description Q ty Eng Weight kg Remarks See Note 203 Pressure gauge PI 71 1 204 Pressure gauge PI 75 1 205 Pressure gauge PI 61 62 1 206 Pressure gauge PI 63 1 207 Press...

Page 262: ...05 11 JDY V type A V type B Part List Item No Description Q ty Eng Weight kg Remarks See Note 101 Thermometer PF1 2x120 x100L V type A 102 Pocket 90L 103 Thermometer PF3 4x650 x100L with pocket V typ...

Page 263: ...1 JDY L type A L type B Part List Item No Description Q ty Eng Weight kg Remarks See Note 201 Thermometer PF1 2x120 x60L 202 Thermometer PF1 2x200 x60L 203 Thermometer PF1 2x120 x100L L type A 204 Poc...

Page 264: ...inlet PT 41 1 208 Charge air cooler outlet PT 21 1 Pressure transmitter 209 Fuel oil engine inlet PAL 51 1 210 Lub oil filter inlet PAL 61 1 211 Lub oil engine inlet PSL 62 1 212 Lub oil turbocharger...

Page 265: ...TE 75 1 223 HT water each cylinder outlet TE 77 a 224 HT water engine outlet TE 76 1 225 LT water air cooler inlet TE 71 1 226 LT water air cooler outlet TE 72 1 227 Charge air cooler outlet TE 21 1 T...

Page 266: ...Exhaust gas turbocharger inlet TE26 d Type D L1 55 232 Exhaust gas turbocharger outlet TE27 1 Type D L1 55 233 Main bearing TE69 Type E 234 Thermo couple amplifier c Q ty of sensor is the same as the...

Page 267: ...o Description Q ty Eng Weight kg Remarks See Note 235 Fuel oil leakage tank LAH 54 1 Type F 236 Prelub Oil engine inlet LAL 65 1 Type G 237 Lub oil sump tank LAL H 68 720rpm 1 238 Lub oil sump tank 90...

Page 268: ...v 1A HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 05 04 PJH Part List Item No Description Q ty Eng Weight kg Remarks See Note 240 Engine control safety RPM SE 47 2 Please see electrical d...

Page 269: ...ctrical signal This pressure transmitter is used for measuring the pressure of Compressed Air Inlet Charge Air HT LT water Fuel oil Lub oil 1 Pressure transmitter test The functional test of the press...

Page 270: ...s been factory calibrated no further adjustment is normally required In case of adjustment it is carried out according to the following procedure 1 Remove the screw and the cap see Fig 3 2 Adjust the...

Page 271: ...2 PT 100 sensor Fig 2 Fig 1 PT100Temperature Sensor Temperature sensor 1 PT 100 sensor for low temp The PT 100 sensor consists of a resistance wire which changes resistance depending on the temperatur...

Page 272: ...testing apparatus producing a constant temperature 3 Check that the measuring value indicated on the Engine Control Panel is equal to the testing apparatus measuring value 4 After the above test the...

Page 273: ...e depending on temperature and is given in the following tables 0 10 20 30 40 50 60 70 80 90 0 0 0 397 0 798 1 203 1 611 2 022 2 436 2 850 3 266 3 681 100 4 095 4 508 4 919 5 327 5 733 6 137 6 539 6 9...

Page 274: ...shows the internal fuel oil system The fuel injection equipment comprises an injection pump a connection block an fuel high pressure block and an injection valve which are installed on each cylinder i...

Page 275: ...equest of the customer The safety filter is a duplex filter of the split type with a filter fineness of 50 micron The filter is equipped with a common three way cock for manual change of both the inle...

Page 276: ...List Section No A51000 Rev 1D HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 07 04 YJB Part List Item No Description Q ty Cyl Weight kg Remarks See Note 100 Fuel Injection Pump Complete 1 3...

Page 277: ...H21 32 Page 2 3 Fuel Injection Pump Ass y Assembly Drawing Part List Section No A51000 Rev 1D HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 07 04 YJB...

Page 278: ...ry valve case 1 8 2 182 Delivery valve 1 8 3 183 Spring 1 8 4 184 Return valve 1 8 5 185 Spring 1 8 6 186 Pin 1 14 114 Socket head bolt 6 15 115 Plunger ass y 1set 16 116 O ring 2 17 117 Back up ring...

Page 279: ...an rag on around fuel injection pump against fuel oil dropping from feed pipes 4 Prepare two fixing bolts M8 and screw fuel injection pump and water jacket by them as shown in fig 2 This is necessary...

Page 280: ...hing adjacent parts 10 Move and place the fuel injection pump on a working stand Mounting a Fuel Injection Pump on the engine Remounting procedure is basically reverse order of dismounting procedure T...

Page 281: ...educe the spring force of fuel injection pump for easier mounting 5 Tighten the nuts for fuel injection pump with increasing torque step by step and one by one diagonally Tightening torque 170 Nm with...

Page 282: ...not a steel brush Be careful not to damage the sealing surface Replace all O rings backup rings and gaskets with new ones Loosen the bolts in several steps 1 Place the pump in a dismantling fixture in...

Page 283: ...ing fixture in upright position Unscrew six socket head bolts fig 8 and dismantle delivery valve case with the O ring fig 9 8 Unscrew two deflectors and pull out them with the gaskets fig 10 Throw awa...

Page 284: ...mentioned criteria and replace the parts with new ones if necessary 1 Pump housing Replace the pump housing if symptoms of heavy abrasion or damage can be observed on sliding bore diameter 2 Plate an...

Page 285: ...than 3 5 mm 5 Plunger assembly Replace the plunger assembly if 1 The clearance between the plunger and the barrel is more than 15 m 2 The erosion of the plunger is marked less than 0 8 mm from notch 3...

Page 286: ...or nicked 2 Corroded 3 Surface coating is damaged 8 Delivery valve spring Replace the delivery valve spring if 1 Cracked or nicked 2 Corroded 9 O rings Replace all these o rings in every disassembly...

Page 287: ...pet assembly etc should be removed in kerosene thoroughly when these parts are replaced And dip them in clean filtered fuel oil before assembly Replace all the O rings and the backup rings with new on...

Page 288: ...e dowel pin on the pump housing are in the same position fig 16 2 Tighten the socket head bolt into the pump housing up to a torque of 100 Nm with a torque wrench fig 17 The gasket is to be replaced 3...

Page 289: ...r spring seat and insert the plunger with the lower spring seat into the barrel so that the vane of the plunger engages the slots in the control sleeve fig 24 Be sure to damage the plunger 10 Slide th...

Page 290: ...w O ring onto the barrel Fasten the socket head bolt up to a torque of 100 Nm with a torque wrench fig 29 15 Release the force on the tappet assembly 16 Tighten the deflector with new gasket into the...

Page 291: ...n pump has been installed or if the deviation of each cylinder pressure is out of tolerance the injection timing should be checked and adjusted which can be adjusted by the thickness of thrust plate a...

Page 292: ...NDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 06 04 YJB 100 191 193 194 A52300 196 195 Part List Item No Description Q ty Cyl Weight kg Remarks See Note 100 Fuel injection valve complete 1 3...

Page 293: ...Page 2 3 Fuel Injection Valve Assembly Drawing Part List 1 stud Section No A52000 Rev 1B HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 06 04 YJB 011 010 008 009 001 004 005 012 006 014 01...

Page 294: ...RIES CO LTD Engine Machinery Division 06 04 YJB Part List Item No Description Q ty Cyl Weight kg Remarks See Note 001 Fuel injection valve body 1 004 O ring 4 005 Dowel pin 2 006 Nozzle nut 1 007 Adju...

Page 295: ...tion valve or uneven injection of fuel oil to combustion chamber or wrong valve opening pressure In order to check correct operation of the fuel injection valve functional test should be performed by...

Page 296: ...Pull out the fuel injection valve from the cylinder head by rotating the nut D of removal device 6 Clean the fuel injection valve and nozzle Take care not to damage or clog the nozzle holes Function T...

Page 297: ...as following process 1 Loosen the locking nut F 2 Turn the adjusting screw G slowly and check valve opening pressure while pumping 3 Adjust the valve opening pressure by the step of 10 bar 4 When pres...

Page 298: ...specially clean surface for contact between the nozzle nut and nozzle as fig 6 in order to prevent leakage of gas by abnormal contact Assembling of Fuel Valve Nozzle optional tool Though the testing d...

Page 299: ...everal times in order to remove carbon and clean the bush before mounting the fuel injection valve on the cylinder head Lapping tool for bush Mounting Fuel Injection Valve on Cyl Head 1 Replace the O...

Page 300: ...Nm 60 Nm molycote 4 Insert the injection pipe correctly as shown in fig 8 and tighten the nut H Tightening torque 10 Nm 30 Nm 60 Nm by three steps with molycote Tightening orders Fig 7 Nozzle nut and...

Page 301: ...Necessary tools and material Drilling machine or electric drill Lapping powder No 1500 No 1800 Cleaning oil gas oil lube oil and compressed air 2 Procedure Fit needle valve into drill chuck Apply lapp...

Page 302: ...ion Valve Reconditioning of Fuel Injection valve Section No M52001 Rev 1A HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 09 05 YTY Photos of needle valve seat before after fit Refer to the...

Page 303: ...el oil for approx one hour prior to dismantling injection valves If this is not possible and the engine has to be shut down from operation on heavy fuel oil the injection valve has to be disassembled...

Page 304: ...pressure to 30 bars by means of the setting screw 2 Criterion of decision All nozzle holes open 1 All nozzle holes open normal 2 Partly clogged Disassemble the fuel injection valve and cleaning or ch...

Page 305: ...means of the nozzle tester It is because the pressure gap between the cylinder chamber and the atmosphere and using the hand pump is hard to make the similar pattern such as fuel injection pump during...

Page 306: ...No Description Q ty Cyl Weight kg Remarks See Note 105 Injection Pipe 1 0 36 106 Stud M12 2 0 07 107 Bush 1 0 11 108 Spherical Washer 2 0 12 109 Plugging Piece 1 114 Hex Socket Bolt M12 2 0 06 115 Set...

Page 307: ...ase of overhauling or replacement of Fuel injection pump Fuel injection valve dismantling and assembling Fuel injection pipe block is required Then Tighten torque by 3 step according to the position o...

Page 308: ...inlet main pipe 1 1 1 1 1 102 Fuel oil return main pipe 1 1 1 1 1 105 Fuel oil inlet branch pipe 5 6 7 8 9 0 26 106 Fuel oil return branch pipe 5 6 7 8 9 0 15 108 Fuel oil leakage pipe 1 1 1 1 1 110...

Page 309: ...protect the pressure instrument from the damage influenced by fluctuation of fuel oil injection pump These dampers should be properly adjusted Below Fig 1 shows the variation of pressure fluctuation b...

Page 310: ...counter clockwise Fig 6 There should be no change of pressure during the spindle is being closed In case of pressure variation loosen the locking nut and tighten the spindle After that check the clos...

Page 311: ...H21 32 Page 1 3 Fuel Oil Filter Assembly Drawing Part List Section No A56000 Rev 1B HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 08 05 JHS...

Page 312: ...Division 08 05 JHS Part List Item No Description Q ty Eng Weight kg Remarks See Note 104 Fuel oil filter complete 1 105 Packing 1 106 Flange 1 107 Packing 1 108 Flange 1 500 Filter catridge 2 501 Hosu...

Page 313: ...on No A56000 Rev 1B HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 08 05 JHS Part List Item No Description Q ty Eng Weight kg Remarks See Note 105 Fuel oil leakage alarm tank ass y 1 604 Pl...

Page 314: ...uple of turns clockwise Simultaneously with turning of the handle the drain cock 2 in bottom of the filter housing should be opened in order to drain of the dirt being scraped of the filter element 3...

Page 315: ...ermostat valve directly uncooled or via L O cooler cooled The cooled and uncooled oil is mixed at the thermostat valve hence the temperature of L O is set to the prespecified value as shown in fig 1 T...

Page 316: ...s determined according to the lubricating oil temperature required Details for the lubricating oil cooler are found in a separate manual The lubricating oil filter is of the duplex paper cartridge typ...

Page 317: ...d be checked all moving parts for wear and any damage and replace worn and damaged parts The thermostat valves are of the wax element type working at fixed temperature range of 60 69 and are installed...

Page 318: ...or lubricating oil has two inlets of downward with same direction The prelubricating oil pump is of the electric motor driven gear type pump which is operated automatically when engine stopped Prelubr...

Page 319: ...Rev 1A HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 05 04 YJB Part List Item No Description Q ty Eng Weight kg Remarks See Note 100 Lub oil pump complete 1 85 191 Bolt 8 193 Tab dowel w...

Page 320: ...olt 1 211 Bolt 5 212 Parallel pin 2 213 O ring 1 214 Bush housing 2 215 Bush housing 1 216 Bush housing 1 217 O ring 1 218 Gasket 1 219 Main spool 1 220 Main spring 1 221 Valve body 1 222 Bolt cover 1...

Page 321: ...Pump 1 Loosen the bolt A as shown in fig 1 and dismount the bolt and the spur gear 2 Loosen the bolts B and dismount the bolts and the cover 3 Dismount the gear wheel shafts Clean all parts thoroughly...

Page 322: ...See Note 100 L O Cooler ass y 1 120 Intermediate piece 4 121 Intermediate piece HT Blank 1 191 O ring 10 192 Socket head bolt 4 193 Nut 4 194 Socket head bolt 8 201 Assembly L O Cooler housing 1 202 P...

Page 323: ...immediately Overhaul of Lubricating Oil Cooler 1 Drain the lubricating oil by loosening the drain plug B on oil cooler housing as shown in fig 1 2 Drain the low temperature cooling water by loosening...

Page 324: ...deter gent which conforms to supplier s recommendation If it is necessary to dismount the oil cooler housing the procedure is as follows 4 Tie the oil cooler housing with a rope and hook up onto a cra...

Page 325: ...cription Q ty Eng Weight kg Remarks See Note 101 L O Filter complete 2 102 L O filter control v v 1 103 O ring 1 104 O ring 2 105 O ring 2 106 O ring 2 108 Bolt 16 110 Plug 2 Included 241 242 243 111...

Page 326: ...ery Division 10 01 SJH Part List Item No Description Q ty Eng Weight kg Remarks See Note 301 Filter cover 2 302 O ring 4 303 Element flange assembly 2 304 Pin bolt 2 305 Cover spring 2 306 Flange spri...

Page 327: ...l filter can be chosen by the filter selection valve It is recommended to use one of the filters normally and the other for stand by use The filter exchange should be carried out during engine stop co...

Page 328: ...d by pulling out the plug more 5 2 4 5 6 2 7 8 5 Open the filter cover and remove the filter cartridge and the 2nd filter Fig 4 5 6 Insufficient drain may cause of spray 6 The 2nd filter can be used a...

Page 329: ...achinery Division 05 04 DYJ Part List Item No Description Q ty Eng Weight kg Remarks See Note 101 L O thermostatic valve complete 1 102 Bolt 8 105 O ring 1 201 L O valve casing 1 202 L O Thermostatic...

Page 330: ...VY INDUSTRIES CO LTD Engine Machinery Division 05 04 DYJ Part List tem No Description Q ty Eng Weight kg Remarks See Note 103 Pressure control valve assembly 1 221 Body 1 222 Adjusting block 1 223 Gui...

Page 331: ...y Drawing Part List Section No A65000 Rev 1B HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 07 07 JCL Part List Item No Description Q ty Eng Weight kg Remarks See Note 101 Pre Lub Oil pump...

Page 332: ...Machinery Division 07 07 JCL Part List Item No Description Q ty Eng Weight kg Remarks See Note 101 Pre Lub Oil pump complete 1 201 Driving cover 1 202 Gear casing 1 203 Pressure relief valve 1 204 Dr...

Page 333: ...1B HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 07 07 JCL Part List Item No Description Q ty Eng Weight kg Remarks See Note 301 End cover 1 302 Piston 1 303 Spindle 1 304 Cap nut 1 305 C...

Page 334: ...Part List Without LT C W Pump Section No A66000 Rev 1A HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 05 04 DYJ Part List Item No Description Q ty Eng Weight kg Remarks See Note 510 L O noz...

Page 335: ...ling water system is designed for using normal fresh water with corrosion inhibitor Both the low and the high temperature system are cooled by fresh water The low temperature cooling water circulates...

Page 336: ...re driven by the gear wheel at the free end of the engine These two pumps are identical but one is for circulating high temperature cooling water and the other is for low temperature cooling water Sea...

Page 337: ...perature in the engine block appropriately as shown in fig 3 The thermostat valve cannot be adjusted and normally no maintenance is required However in some cases it is necessary to clean or replace v...

Page 338: ...ousings Check control temperature range marked on each valve Do not mix the valve elements on a housing All the valve housings for L T W H T W and lubricating oil have same diameter and mountable into...

Page 339: ...H21 32 Page 1 2 C W Pump Assembly Assembly Drawing Part List Without LT C W Pump Section No A71000 Rev 1B HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 06 04 YJB...

Page 340: ...casing 1 202 Pump cover 1 203 Shaft 1 204 Spur gear 1 205 Impeller 1 206 Retaining ring 1 209 Bearing 1 210 Bearing 1 211 Socket head bolt 8 212 O ring 2 213 O ring 3 214 Mechanical seal 1 215 Oil se...

Page 341: ...right angle The seal cover of 1Z bearing should be assembled toward impeller as shown in Fig 1 2 The oil seal which has a groove on the upper direction is mounted on pump housing by tool as shown in F...

Page 342: ...with loctite 620 and tighten as shown in Fig 3 4 The seat ring of mechanical seal is greased on outside and inserted as shown in Fig 4 5 The shaft which is sub assembled together with bearing is mount...

Page 343: ...sing is turned as shown in Fig 6 7 The rotating part of mechanical seal is assembled as shown in Fig 7 8 In order to remove oil on shaft thread and bolt before loctite coating degreaser should be spra...

Page 344: ...spur gear is assembled and the bolt is coated with loctite 242 and tighten by torque 280Nm as shown in Fig 9 10 The impeller is tightened by torque 120Nm as shown in Fig 10 11 O ring is coated with gr...

Page 345: ...Division 08 01 YJB 12 13 12 The pump housing is mounted on the front end block of the engine And tighten the socket head bolt on the pump housing 13 The pump cover is mounted on the pump housing And t...

Page 346: ...ES CO LTD Engine Machinery Division 05 04 DYJ Part List Item No Description Q ty Eng Weight kg Remarks See Note 101 Blank piece ass y For L T thermo v v 1 102 H T thermostatic valve complete 1 29 9 10...

Page 347: ...gine Machinery Division 05 04 DYJ Part List Item No Description Q ty Eng Weight kg Remarks See Note 105 Bolt 4 106 Gasket 1 109 Spring washer 4 131 Control valve ass y 1 231 Valve spindle 1 232 Flange...

Page 348: ...LTD Engine Machinery Division 05 04 DYJ Part List Item No Description Q ty Eng Weight kg Remarks See Note 101 Jacket water inlet pipe 1 102 Jacket water outlet pipe 1 1 103 Jacket water outlet pipe 2...

Page 349: ...t Q ty Eng Item No Description 5 cyl 6 cyl 7 cyl 8 cyl 9 cyl Weight kg Remarks See Note 711 Connection piece Cyl head 4 5 6 7 8 712 O ring 18 22 26 30 34 713 Stop piece 8 10 12 14 16 716 Bolt 15 17 19...

Page 350: ...etc The turbocharger is a radial uncooled type with high efficiency and mounted on the feed block of the engine And the water washing systems for the compressor and turbine are supplied as standard Th...

Page 351: ...causes contamination of turbine blades and nozzle rings of turbocharger The results are low turbine efficiency increased exhaust gas temperature higher charging and firing pressures and lower engine...

Page 352: ...eaning compressor engine should run under load for at least 10 to 15 minutes Cleaning of Turbine Components 1 Supply the pipe arrangement for cleaning the turbine components by the engine maker as sho...

Page 353: ...erating hours The recommended temp range for the washing water is 20 to 40 Fig 2 Pipe arrangement for cleaning of the turbine side Table 1 Cleaning parameter Type Temperature before turbine TTi Absolu...

Page 354: ...M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 142 DETAIL K 910 911 141 Part List for 5H21 32 Item No Description Q ty Eng Weight kg Remarks See Note 000 Intake air duct ass y 1 110 Interpiece diffuser...

Page 355: ...901 414 330 292 910 289 909 282 281 291 280 340 903 420 906 903 906 901 419 294 295 902 906 425 906 906 903 425 907 905 901 Part List for 5H21 32 Item No Description Q ty Eng Weight kg Remarks See Not...

Page 356: ...kg Remarks See Note 294 Exhaust pipe 1 295 Exhaust pipe 1 330 Compensator 4 340 Compensator 2 414 Support 1 419 Connection piece 1 420 Exh Duct support 5 421 Blind Flnage 5 422 Packing 5 425 Support...

Page 357: ...H21 32 Page 1 2 T C Mounting for Pulse System Assembly Drawing Part List Section No A83000 Rev 1A HYUNDAI HEAVY INDUSTRIES CO LTD Engine Machinery Division 05 04 JSC...

Page 358: ...rbocharger 1 See Detail T C manual 110 Support for T C gas outlet 1 18 5cyl 16 6 cyl 20 7 cyl 20 8 cyl 111 Bolt 20 9 cyl 121 Support for turbocharger 1 35 3 124 Plug 2 125 Gasket 2 128 O ring 1 129 O...

Page 359: ...t Item No Description Q ty Eng Weight kg Remarks See Note 100 Air cooler 1 110 Water mist catcher 1 111 Gasket for air cooler 1 119 Bolt 4 120 Cover for air cooler 1 122 Gasket for air cooler cover 1...

Page 360: ...plates and tubes to transfer the heat properly Also be sure to inspect the gasket condition in the charge air cooler Inspect the charger air cooler at regular intervals for a long service life of the...

Page 361: ...the fins are not damaged during the maintenance Damaged fins result in an increased the pressure drop across air cooler Check for corrosion Make sure that fouling and deposits in the intermediate pie...

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